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END-O-SLUDG an innovative holistic system approach to sludge management. Author: Dr. Son Le, MBE (presenting author Herman Sioen, WATERLEAU) Meeting: “ La gestion innovante des boues d’épuration à l’échelle européenne ” (CEME Charleroi, 22 October 2013) . AIM & OBJECTIVE. - PowerPoint PPT Presentation
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END-O-SLUDGan innovative holistic system approach to sludge
management
Author: Dr. Son Le, MBE (presenting author Herman Sioen, WATERLEAU)Meeting: “La gestion innovante des boues d’épuration à l’échelle européenne” (CEME Charleroi, 22 October 2013)
2
• Aim: to have marketable sludge derivatives from sustainable processing of wastewater in a highly integrated treatment plant.
• Objective: To research, develop and demonstrate a toolkit of novel processes together with development the market and integration methodologies that can be applied for sustainable sludge management.
AIM & OBJECTIVE
EU FP7 END-O-SLUDG Project, Author: 4
5. Management and sustainability• Pathogen risk assessment • Long-term soil impact assessment • Technology assessment including LCA, EIA, SEA, Social Political and Legal • Integration methodologies and implementation strategy
2. Sludge treatment• Pre-treatments• Inverted phase fermentation• Digestion intensification• Competitive exclusion
1. Sludge reduction• Enhanced solid removal• COD removal• P removal
Sludge derivatives Struvite Ammonium phosphate Ammonium bicarbonate Neighbourly cake Bio-granule Organo mineral fertiliser
4. Market development• End-o-Waste• Product trials• Nutrient management • Economic assessment
3. Downstream processing• N & P recovery• Dewatering• Granulation• Dehydration• Nutrient formulation
5. Management and sustainability• Pathogen risk assessment • Long-term soil impact assessment • Technology assessment including LCA, EIA, SEA, Social Political and Legal • Integration methodologies and implementation strategy
2. Sludge treatment• Pre-treatments• Inverted phase fermentation• Digestion intensification• Competitive exclusion
1. Sludge reduction• Enhanced solid removal• COD removal• P removal
Sludge derivatives Struvite Ammonium phosphate Ammonium bicarbonate Neighbourly cake Bio-granule Organo mineral fertiliser
4. Market development• End-o-Waste• Product trials• Nutrient management • Economic assessment
3. Downstream processing• N & P recovery• Dewatering• Granulation• Dehydration• Nutrient formulation
Scopeof
Project
5
1.1 Sludge arising from conventional works
1° sediment Tertiary treatment
Treated effluent
Sludge Sludge Sludge
Advanced treatment
Biosolids
Biogas Anaerobic digester
2° sediment
Sludge
Activated sludgeor trickling filter
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1.1 Concept of Sludge Reduction
1° sediment Tertiary treatment
Treated effluent
Sludge Sludge Sludge
Advanced treatment
Biosolids
Biogas Anaerobic digester
DAF
P sludge
BIOSORBENT
VFA
7
1.3 DAF performance
Trials in The Netherlands
TSS removal from >99% COD removal from up to 80%ASP load reduction 59%
8
1.4 Sorbent performance
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 20 40 60 80 100 120
Volume of Sample (ml)
Frac
tion
of C
OD
(mg/
L)
PicaBiol
NORIT 1240W
Aquasorb 200
9
• Pre-treatments• Inverted phase fermentation• Digestion intensification• Competitive exclusion
2. Sludge Treatment
10
2.1 Ultrasonic sonication
Initial Ultrasound Fermentation0
5000
10000
15000
20000
25000
Untreated 3579 7157 10736 13917 21074
CODs
(mg/
L)
Ultrasound pre-treatment of secondary sludge from Baíña WTP(numbers = specific energy applied, kJ/kgTS)
Ultrasonic has most pronounced effect on SAS compared to other sludge types
11
2.2 Inverted Phase Fermentation
12
2.3 Digestion intensification
0 10 20 30 40 50 60 70 80 90 1000
5
10
15
20
25
30
0
5
10
15
20
25
30R1 BIOGAS R1 CH4
Days
Biog
as (L
)
CH4
(L)
HRT 3d HRT 2d HRT 1.5d HRT 1d HRT 0.83d
13
2.4 Competitive exclusion
1.0E+00
1.0E+01
1.0E+02
1.0E+03
1.0E+04
1.0E+05
1.0E+06
1.0E+07
1.0E+08
1.0E+09
1.0E+10
1.0E+11
0 h 48 h
Time (h)
E. c
oli
conc
entra
tion
(cfu
/g D
S)2 day control
2 day experiment
4 day control
4 day experiment
E. coli culture
Competition culture:BROM1 and E. coli
Probiotic culture
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3. Downstream Processing
Liquor treatment
High quality product for end-o-waste (OMF Manufacture)
Resource recovery (N & P)
15
Product requirement:Granular, free flowing, dust free3-5mm size, >1.3 g/ccGuaranteed nutrient content
Issues:• Energy intensive process• High wearing / high maintenance• Explosion risk
3. 1 The OMF challenge
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3. 2 Two-stage OMF manufacturing process
17
3. 3 First stage – Waterleau PUTTART® technology
coated pellets
incondensables
boiler
oil pump
air, fuel
cooling water
condenser
condensate to
treatment
Dry granules (>90%DS) to storage
Green granules (<65%DS)
to dehydration unit
sieve
granule recirculation
coater
LilliPutt ® pilot
granulator
granulesve
rtica
l tra
nspo
rt
sludge pump
Digested sludge cake
vapours
warm water
Nutrients(urea/TSP)
Nutrient dosing
18
3. 4 second stage – Valsave THERMALOOP™ technologyTHERMALOOP™ Innovative solution for biogranule manufacture
1
5
610
1. Dehydration chamber2. Air circulator3. Air scrubber4. Water circulator5. Heat recovery unit
6. Compressor7. Air heater8. Green granules9. Biogranules10. Wastewater
2
4
7
55°C 62°C
42°C
36°C
42°C
31°C 72°C
41°C
8 9
3
THERMALOOP™ Innovative solution for biogranule manufacture
1
5
610
1. Dehydration chamber2. Air circulator3. Air scrubber4. Water circulator5. Heat recovery unit
6. Compressor7. Air heater8. Green granules9. Biogranules10. Wastewater
2
4
7
55°C 62°C
42°C
36°C
42°C
31°C 72°C
41°C
8 9
3
19
3.5 OMF Pilot plant (Ellesmere Port)
Dehydration unit(artist impression)
Granulator unit
PUTTART® VERTICAL DISC DRYER-GRANULATOR
Cold structure
Shell (insulated)
Trays
Raking arms with ploughs
Central rotating shaft
Drive
Reference plant: Poznan, Poland3 lines of each 3.1 TPH H2O evap.
MOUNTING ON SITE
LILLIPUTT®
IN OPERATION
LILLIPUTT®
First granules
LilliPutt® Test plant in operation
KEY DATA Technology: LilliPutt® Plant Capacity
Dry solids 2.4 TPD Wet Cake 12 TPD Evaporation 10 TPD N° of lines 1
Wet Sludge Data Digested secondary municipal sludge 21% dry solids
Dry Sludge Data >90% dry solids
Start of operation: November 2012 Current status: test completed, plant will be decommissioned this month Site location: Ellesmere Port, (Manchester), UK
LILLIPUTT®
24
Aim: To develop a distinct knowledge base by which farmers and agriculturalists integrate OMF-based products.
Two products to be developed:Grassland application (NPK: 10-4-0)Arable crop application (NPK: 3-8-0)Note : Digested sludge = NPK 4-5-0
Market demand key factor in gaining End of Waste status
4. Market Development
4.1 Plot trials at Broxton (Cheshire)
4.2 Plot trials at Broxton (Cheshire)
Deeks LK, Chaney K, Murray C, Sakrabani R, Gedara S, Le MS, Tyrrel S, Pawlett M, Read R, Smith GH (2013). Field evaluation of a sewage sludge derived novel organo-mineral fertilizer on combinable crops. Agronomy for Sustainable DevelopmentDOI 10.1007/s13593-013-0135-z
27
• Product status is key aim of the OMF development• Legal status is complex• Demonstrate equivalence with existing fertilisers• Development of specifications for OMF• Continuing plot/field trials• Development of grower protocols• Engage with Regulators
4.3 End of Waste: Practical Steps
28
• Sustainable, renewable sources of phosphate are required.
• OMF has the potential to fulfil market requirements• Unlike UK the application of biosolids to land is not
universally accepted by all stakeholders. E.g. Netherlands recycling is prohibited.
• END-O-SLUDG working to address these issues
4.4 End of Waste: Market Development
29
CONCLUSION END-O-SLUDG aims to create a portfolio of useful new products
from sludge that meet End of Waste as part of a new concept for sewage sludge management in Europe.
This involves development of new technologies for:• Sludge volume reduction• More efficient sludge treatment• Economical downstream processing• Renewable source of P that could sustainably support crop
production
Results so far have been very promising
Acknowledgement: The research leading to these results has received funding from the European Union Seventh Framework Programme (FP7-ENV.2010.3.1.1-2 ENV) under grant agreement N° 265269.
www.end-o-sludg.eu
Dr. Son Le, [email protected]
Herman [email protected]